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Powder Metallurgy
- 11. Process Capabilities ME 355 Sp’06 W. Li A: highest, B: median, C: lowest Con’tional HIP Injection Molding (IM) Precision IM Preform Forging Metal All All (SA, SS) All (Steel, SS) All Steel, SA Surface detail B B-C B A A Mass, kg 0.01-5(30) 0.1-10 10-7000 (e) 0.01-0.2 0.005-0.2 0.1-3 Min. section, mm 1.5 1 0.1 3 Min. core diam. mm 4-6 1 0.2 5 Tolerance +/-% 0.1 2 0.3 0.1 0.25 Throughput (pc/h) 100-1000 5-20 100-2000 100-2000 200-2000 Min. quantity 1000-50,000 1-100 10,000 10,000 100,000 Eq. Cost B-C A A-B A-B A-B
- 12. Design Aspects ME 355 Sp’06 W. Li (a) Length to thickness ratio limited to 2-4; (b) Steps limited to avoid density variation; (c) Radii provided to extend die life, sleeves greater than 1 mm, through hole greater than 5 mm; (d) Feather-edged punches with flat face; (e) Internal cavity requires a draft; (f) Sharp corner should be avoided; (g) Large wall thickness difference should be avoided; (h) Wall thickness should be larger than 1 mm.